Broken Headlights

I recently drove my 2019 TRD Pro across the country on the TransAmerica Trail. When I got to Colorado I realized the driver's side headlight was rattling around as I bounced around the trails. By the time I got to a dealership in Denver, the top plastic tab broke and the headlight had dropped down behind the fender. The Toyota dealership wasn't sure what the issue was and zip tied the light up for me since I was not at my home dealer and it was going to take 2-3 days to order a new unit anyhow. About a week after that, the same exact issue happened with the passenger headlight. Now they both are broken and I had to use zip ties to minimize any additional damage since they were banging against the fender. When I took it to Toyota back home, they are insisting that this was caused by some sort of impact but I did not hit anything and this is clear since there is no damage elsewhere on the truck. They wanted $1500 for EACH headlight to replace them plus a few hundred dollars for minor body work where the fenders have gotta misaligned and the paint rubbed on. I'm fighting it with corporate but wondered if anyone else has had this issue? I heard something similar was happening with FJ Cruisers a few years ago. Somewhat frustrating that the most 'capable' off-roading Tacoma and expensive TRD Pro had this sort of issue with just 10k miles on the odometer.

 

Did you at least wash it before taking it to the dealer ??

 

I've never had an issue and I'm not easy on my truck. Was the truck clean when u brought it in? I know those tabs are weak.

 

I’d say that aftermarket bumper being bolted to the frame and the body on bushings bolted to frame made contact and damaged the headlights

 

What say you op? Any marks at the bottom of the headlight?

 

Any marks on the skid plate ?

 

Looks like the support from the oem bumper under the light is gone with that bumper. And only the tabs holding it. Probs why they with all the off-road they snapped

 

I hope you washed that bish before taking it in. with all that mud and dirt everywhere, of course they're going to insist you did it while offroading.

 

No I didn't wash it when I took it in since I literally just got off the trail and went straight to the dealer in Denver. I will be washing it thoroughly whenever I take it back once I hear back from Toyota North America. There is no damage to the bottom of the light where the bumper lines up and the lens has no cracks or scrapes. There are minor scrapes on the skid plate where I hit a tree root or rock but nothing major. It does have a screw on either side where the factory bumper attaches and there is a bolt there which should provide support. C4 Fab is a reputable fab shop and I'm sure they have sold a ton of these bumpers. I feel like if the bumper was causing this, C4 would have heard by now or others with the Overland front bumper would have the same issue.

 

Holy fawck...that engine bay...

 

Ha I get it was filthy but, again, if I hit something (a) I would know and just say so and (b) there would be scrapes on the bumper, skid plate, hoops or something. So I don't get how they can make that assertion.

 

do you have any other broken tabs of anything else...or missing retainer clips?

 

Nothing else, just those the top tab on each of the headlights. Exact same tab on the driver as the passenger.

 

point that out to the stealership as well. no scuffs anywhere and no other broken tabs etc...

 

I predict they're going to tell you to pound sand.....politely

 

Thanks all, will do. I expect to hear back from the customer service manager from Toyota North America tomorrow/Tuesday so we will see. Just wanted to see if by chance anyone had something similar occur. The dealership also claimed to complete the 15k service but actually didn't do a thing to the truck after having it for a week so any trust or benefit of the doubt is blown with them.

 

That's what I'm afraid of as well Plain Jane. Which is messed up in my opinion. You buy the most expensive Taco they make, use it for off-roading, which it is supposedly made for, and cheap plastic clips snap. I would HOPE they stand behind their products but I am not optimistic if I'm being honest.

 

Almost makes me wanna dump some jb weld in those ribs to reinforce it. Did the same thing with those 3m hooks for your wall. The hooks would snap, a little jb weld was just perfect

 

They see the mud/dirt and that bumper that looks very close to the headlights. And it just so happened that both sides broke?

You have an uphill battle